脉冲磁致振荡凝固细晶技术基础研究
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摘要
本文提出了一种全新的凝固组织细化技术——脉冲磁致振荡凝固细晶技术。采用自行研发的脉冲磁致振荡实验系统和EMV定向凝固实验台,结合微分热分析技术,全面研究了脉冲磁致振荡对金属凝固组织和凝固行为的影响,获得了脉冲磁致振荡细化金属凝固组织的作用规律,揭示了脉冲磁致振荡细化金属凝固组织的本质。
应用经典电动力学理论及声学理论分析了脉冲磁致振荡作用下纯金属的凝固过程,提出了脉冲磁致振荡下液态金属凝固过程及凝固组织细化模型。脉冲电磁场与其在金属熔体表面产生的感应电流共同作用,产生洛伦兹力f=J×B,该力垂直于试样侧表面而指向试样轴心。由于电流的“趋肤效应”,凝固表面发生振荡。同时,由于固相电导率成倍增加,感应电流在晶核中强度增加,由此在晶核上产生一个由外向里的力,该力将促使从凝固表面脱落的自由晶核向熔体运动。当晶核运动到一定深度离开了趋肤效应区后,由于运动速度减慢而聚集,原来尺寸较小的晶核就可能形成多孔组织。当该组织的尺度与脉冲磁致振荡的振动波长相当时,它会反射脉冲磁致振荡产生的振动波,而获得相应的压力并使晶核得以继续向熔体内部运动。当晶核运动到熔体内部时,由于周围液体温度较高,可能被熔化为若干更小的晶核,由此增加了液态金属中晶核的数目,从而形成等轴晶组织。
系统研究了浇注后不同冷却阶段脉冲磁致振荡处理对纯铝凝固组织的影响。实验结果显示,在脉冲磁致振荡孕育处理、脉冲磁致振荡凝固处理以及脉冲磁致振荡全程处理三种技术条件下,后两者对纯铝组织的细化效果较佳,可以获得细小等轴晶。通过隔离网实验发现,明显的组织细化效果出现在靠近处理表面的隔离网外区域,而隔离网内熔体的凝固组织没有明显变化。由此得出振荡细化核心的来源是振荡处理时从处理区域表面的型壁上异质形核后脱落的晶核,也即振荡产生的结晶雨作用。通过系统的实验建立了平均晶粒尺寸与脉冲磁致振荡参数的定量关系,证明脉冲磁致振荡的表面振动以及振荡波的传播所产生的声压是晶核迁移的动力。通过对不同屏蔽条件的熔体施加脉冲磁致振荡,发现当凝固外壳或铸型的电导率较凝固熔体小时,其对脉冲磁致振荡的屏蔽作用是较小的,当凝固外壳或铸型的电导率较凝固熔体大时,将对脉冲磁致振荡形成一定的屏蔽作用,但如果适当提高脉冲磁致振荡的处理强度,也能产生较好的细化效果。
研究表明,脉冲磁致振荡能够明显细化锡锑合金的凝固组织,使晶粒尺寸变小,同时减弱了宏观偏析。对脉冲磁致振荡作用下锡锑合金凝固组织中β相的研究表明,铸锭中的β相在脉冲磁致振荡作用下尺寸变小,而且脉冲磁致振荡强度越高,晶粒尺寸减小越显著,晶粒数量增多,分布弥散。说明脉冲磁致振荡可以促进晶核增殖,从而大大细化组织。
脉冲磁致振荡对铁素体不锈钢凝固组织具有显著细化作用。在一定的范围内增大处理频率和强度参数,脉冲磁致振荡对铁素体不锈钢凝固组织的细化效果及等轴晶区面积迅速递增。在适当的参数条件下等轴晶区比例可以达到100%。当脉冲磁致振荡参数过大时,由于焦耳热过大,铁素体不锈钢凝固组织细化效果反而变差。
通过脉冲磁致振荡作用下的定向凝固实验研究,发现在同一温度梯度和晶体生长速度下,随着磁致振荡强度的增加,铝铜合金定向凝固组织中的柱状晶数增多,柱状晶一次枝晶间距变小。实验发现,脉冲磁致振荡可以加速固液界面的平界面(?)胞状界面(?)胞枝界面的转化。分析认为导致界面失稳的主要原因是由脉冲磁致振荡产生的剪切力对柱状晶的作用。
In this paper,a new developed technique,pulse magneto oscillation(PMO),was introduced.The effects of PMO on the solidification structures and behavior of metals were systematically studied by employing thermal analysis and directional solidification techniques. The experimental devices were combined with the self-developed facilities including high voltage pulse power source,solidification tester and EMV directional solidification device etc.As a result, the regularity of structure evolution under the influence of PMO was obtained,and the mechanism of structure refinement was discussed.
Based on the analysis of solidification process of pure metals by classical electrodynamics and acoustics,the model about the molten metals and mechanism of solidification structure refinement under PMO was presented.Generally,Lorentz force f=J×B can be generated due to the combined effects of pulsed magnetic field and the induced current.This force orients from the surface to the inside of the specimen,causing an intense oscillation on the surface of melt on account of the "skin effect" of current.Meanwhile,a pulsed force from surface to inside was produced on the nucleus owing to the extremely high difference between conductance of the solid and liquid of the metal and thereby an increase of the induced current appeared.As a result,the free nucleus fell from the surface were forced to move inside.When the original small nucleus moved deeper enough out of the area of the "skin effect" area,they moved slowly and got together to form the nucleus clusters with many holes.As the size of these nucleus clusters exceeds exceeded some critical size which is was bigger enough to reflect the oscillation wave,nucleus clusters could be forced to move into the melt by the press of the wave.When the nucleus clusters reaches reached inside of the melt,it might be melt into some smaller nucleus because of around higher temperature of the melt around it and therefore the number of the nucleus in the melt was increased and equiaxed crystals were formed.
The PMO was applied at three different stages during the cooling process of aluminum melt, i.e.incubation period,solidification stage and whole course from melt to total solid.The results showed that optimum refinement was achieved by second and third processes,with a change from coarse columnar crystals to fine equiaxed ones.In the experiment with stainless steel net in the melt,the solidification structure refinement appeared between the stainless steel net and the surface,but inside the stainless steel net the solidification structure was coarse columnar crystals. It was deemed that the reason of solidification structure refinement was the increasing of nucleus inside the melt which fell off from the mould wall into the surface near the place treated by PMO, i.e.crystal rain effect was produced by the oscillation.Based on another systemic experimental result,the quantificational relation between the average grain size and the PMO parameters was established.It was found that the press produced by oscillation wave resulted from the surface oscillation of the PMO promoted the nucleus inside.In different shield condition experiments treated by the PMO,the results showed that the shield effect was less with the smaller conductance of mould and greater with the bigger conductance of model than the melted metal, but the solidification structure could be refined if the intensity of the PMO was increased.
It was shown that the solidification structure was obviously refined and the macro-segregation was improved by PMO treatment.The study about the effect of PMO on theβphase of the solidification structure of Sn-10.4%Sb indicated that the size of theβphase in the cast ingot diminished.Clearly,the more intensity of the PMO,the more obviously diminished effect was achieved.It is reasonable to come to the conclusion that the PMO can break the dendrite and multiply the nucleus,and therefore largely refine solidification structure.
In normal solidification condition,PMO can obviously refine the macrostructure of ferrite stainless steel.When the treatment frequency and intensity of PMO was increased the size of equiaxed grains was correspondingly decreased and the equiaxed grain area was increased.In an optimal intensity range,the proportion of the equiaxed grains can reach as high as 100%.The macrostructure became coarse again when the intensity of pulse magneto oscillation was reasonably increased because the Joule heart produced by pulse magneto oscillation was too much to solidify.
Besides,the directional solidification under the effect of PMO was carried out.As the increase of magnetic intensity,the amount of grains was increased and the space between the first dendrite arm spacing of columnar grain was decreased at a given temperature gradient and crystal growing rate.The results showed that the PMO could accelerate the transformation of the liquid-solid interface in the mode of plane interface(?)cell interface(?)cell/dendrite interface.It was deemed that this transformation was resulted from the effect of cut force of PMO on the columnar grains.
应用经典电动力学理论及声学理论分析了脉冲磁致振荡作用下纯金属的凝固过程,提出了脉冲磁致振荡下液态金属凝固过程及凝固组织细化模型。脉冲电磁场与其在金属熔体表面产生的感应电流共同作用,产生洛伦兹力f=J×B,该力垂直于试样侧表面而指向试样轴心。由于电流的“趋肤效应”,凝固表面发生振荡。同时,由于固相电导率成倍增加,感应电流在晶核中强度增加,由此在晶核上产生一个由外向里的力,该力将促使从凝固表面脱落的自由晶核向熔体运动。当晶核运动到一定深度离开了趋肤效应区后,由于运动速度减慢而聚集,原来尺寸较小的晶核就可能形成多孔组织。当该组织的尺度与脉冲磁致振荡的振动波长相当时,它会反射脉冲磁致振荡产生的振动波,而获得相应的压力并使晶核得以继续向熔体内部运动。当晶核运动到熔体内部时,由于周围液体温度较高,可能被熔化为若干更小的晶核,由此增加了液态金属中晶核的数目,从而形成等轴晶组织。
系统研究了浇注后不同冷却阶段脉冲磁致振荡处理对纯铝凝固组织的影响。实验结果显示,在脉冲磁致振荡孕育处理、脉冲磁致振荡凝固处理以及脉冲磁致振荡全程处理三种技术条件下,后两者对纯铝组织的细化效果较佳,可以获得细小等轴晶。通过隔离网实验发现,明显的组织细化效果出现在靠近处理表面的隔离网外区域,而隔离网内熔体的凝固组织没有明显变化。由此得出振荡细化核心的来源是振荡处理时从处理区域表面的型壁上异质形核后脱落的晶核,也即振荡产生的结晶雨作用。通过系统的实验建立了平均晶粒尺寸与脉冲磁致振荡参数的定量关系,证明脉冲磁致振荡的表面振动以及振荡波的传播所产生的声压是晶核迁移的动力。通过对不同屏蔽条件的熔体施加脉冲磁致振荡,发现当凝固外壳或铸型的电导率较凝固熔体小时,其对脉冲磁致振荡的屏蔽作用是较小的,当凝固外壳或铸型的电导率较凝固熔体大时,将对脉冲磁致振荡形成一定的屏蔽作用,但如果适当提高脉冲磁致振荡的处理强度,也能产生较好的细化效果。
研究表明,脉冲磁致振荡能够明显细化锡锑合金的凝固组织,使晶粒尺寸变小,同时减弱了宏观偏析。对脉冲磁致振荡作用下锡锑合金凝固组织中β相的研究表明,铸锭中的β相在脉冲磁致振荡作用下尺寸变小,而且脉冲磁致振荡强度越高,晶粒尺寸减小越显著,晶粒数量增多,分布弥散。说明脉冲磁致振荡可以促进晶核增殖,从而大大细化组织。
脉冲磁致振荡对铁素体不锈钢凝固组织具有显著细化作用。在一定的范围内增大处理频率和强度参数,脉冲磁致振荡对铁素体不锈钢凝固组织的细化效果及等轴晶区面积迅速递增。在适当的参数条件下等轴晶区比例可以达到100%。当脉冲磁致振荡参数过大时,由于焦耳热过大,铁素体不锈钢凝固组织细化效果反而变差。
通过脉冲磁致振荡作用下的定向凝固实验研究,发现在同一温度梯度和晶体生长速度下,随着磁致振荡强度的增加,铝铜合金定向凝固组织中的柱状晶数增多,柱状晶一次枝晶间距变小。实验发现,脉冲磁致振荡可以加速固液界面的平界面(?)胞状界面(?)胞枝界面的转化。分析认为导致界面失稳的主要原因是由脉冲磁致振荡产生的剪切力对柱状晶的作用。
In this paper,a new developed technique,pulse magneto oscillation(PMO),was introduced.The effects of PMO on the solidification structures and behavior of metals were systematically studied by employing thermal analysis and directional solidification techniques. The experimental devices were combined with the self-developed facilities including high voltage pulse power source,solidification tester and EMV directional solidification device etc.As a result, the regularity of structure evolution under the influence of PMO was obtained,and the mechanism of structure refinement was discussed.
Based on the analysis of solidification process of pure metals by classical electrodynamics and acoustics,the model about the molten metals and mechanism of solidification structure refinement under PMO was presented.Generally,Lorentz force f=J×B can be generated due to the combined effects of pulsed magnetic field and the induced current.This force orients from the surface to the inside of the specimen,causing an intense oscillation on the surface of melt on account of the "skin effect" of current.Meanwhile,a pulsed force from surface to inside was produced on the nucleus owing to the extremely high difference between conductance of the solid and liquid of the metal and thereby an increase of the induced current appeared.As a result,the free nucleus fell from the surface were forced to move inside.When the original small nucleus moved deeper enough out of the area of the "skin effect" area,they moved slowly and got together to form the nucleus clusters with many holes.As the size of these nucleus clusters exceeds exceeded some critical size which is was bigger enough to reflect the oscillation wave,nucleus clusters could be forced to move into the melt by the press of the wave.When the nucleus clusters reaches reached inside of the melt,it might be melt into some smaller nucleus because of around higher temperature of the melt around it and therefore the number of the nucleus in the melt was increased and equiaxed crystals were formed.
The PMO was applied at three different stages during the cooling process of aluminum melt, i.e.incubation period,solidification stage and whole course from melt to total solid.The results showed that optimum refinement was achieved by second and third processes,with a change from coarse columnar crystals to fine equiaxed ones.In the experiment with stainless steel net in the melt,the solidification structure refinement appeared between the stainless steel net and the surface,but inside the stainless steel net the solidification structure was coarse columnar crystals. It was deemed that the reason of solidification structure refinement was the increasing of nucleus inside the melt which fell off from the mould wall into the surface near the place treated by PMO, i.e.crystal rain effect was produced by the oscillation.Based on another systemic experimental result,the quantificational relation between the average grain size and the PMO parameters was established.It was found that the press produced by oscillation wave resulted from the surface oscillation of the PMO promoted the nucleus inside.In different shield condition experiments treated by the PMO,the results showed that the shield effect was less with the smaller conductance of mould and greater with the bigger conductance of model than the melted metal, but the solidification structure could be refined if the intensity of the PMO was increased.
It was shown that the solidification structure was obviously refined and the macro-segregation was improved by PMO treatment.The study about the effect of PMO on theβphase of the solidification structure of Sn-10.4%Sb indicated that the size of theβphase in the cast ingot diminished.Clearly,the more intensity of the PMO,the more obviously diminished effect was achieved.It is reasonable to come to the conclusion that the PMO can break the dendrite and multiply the nucleus,and therefore largely refine solidification structure.
In normal solidification condition,PMO can obviously refine the macrostructure of ferrite stainless steel.When the treatment frequency and intensity of PMO was increased the size of equiaxed grains was correspondingly decreased and the equiaxed grain area was increased.In an optimal intensity range,the proportion of the equiaxed grains can reach as high as 100%.The macrostructure became coarse again when the intensity of pulse magneto oscillation was reasonably increased because the Joule heart produced by pulse magneto oscillation was too much to solidify.
Besides,the directional solidification under the effect of PMO was carried out.As the increase of magnetic intensity,the amount of grains was increased and the space between the first dendrite arm spacing of columnar grain was decreased at a given temperature gradient and crystal growing rate.The results showed that the PMO could accelerate the transformation of the liquid-solid interface in the mode of plane interface(?)cell interface(?)cell/dendrite interface.It was deemed that this transformation was resulted from the effect of cut force of PMO on the columnar grains.
引文
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